Oil-free rotary screw air compressor delivers up to 14% energy improvements

CompAir has extended its range of DX, oil-free rotary screw air compressors with the launch of the new DX90-160 (RS) series, offering up to 14% improvement in energy efficiency and up to 8% higher flow compared with industry standards.

The range has been designed to offer best-in-class energy performance, excellent reliability and reduced lifecycle costs – in an oil-free compressor, which is Class Zero certified according to ISO 8573-1:2010. This means there is virtually no risk of contamination in the production process, making it ideal for applications where high levels of air purity are essential.

The new range includes fixed and variable-speed models from 90 to 160kW, and includes 7.5, 8,5 and 10.5bar pressure variants.

A newly designed, two-stage airend delivers up to 9% improvement in capacity. Built to last, the ultra-durable airend rotor and housing coating, coupled with stainless steel rotors in the second stage, helps extend longevity. A separate air intake also ensures that cooler air is supplied to the airend, helping improve performance further still.

Compressor rotor surfaces can deteriorate over time, so the airend is protected with UltraCoat, an advanced rotor and housing protection process with excellent adhesion properties and temperature resistance.

Maintenance has been considered at every stage of the airend design. Its rugged bearing design eliminates the need for balancing pistons, helping to reduce complexity and service costs.  Internal oil lines also eliminate the risk of leaks, while reducing the number of hoses and piping for simpler and quicker maintenance.

An IE5, ultra-premium hybrid reluctance motor (HRM) on all variable-speed models delivers exceptional efficiency at any load. With an IP55 rating to protect against dust and water ingress, the motor is air cooled with low starting power consumption for a long life. 

Reliability is assured, in constant 24/7 operations thanks to lower bearing temperatures, which help extend lifetime and lubrication intervals. Variable-speed models include extensive turndown capabilities of up to 71% ensure that air output is matched precisely to plant demand.

The web-integrated Delcos i 10 controller with touch screen display provides real-time information, helping operators to adjust the compressor parameters for optimum efficiency. The information is structured in five main display pages and an optional energy monitoring system provides at-a-glance energy data including consumption, cost and efficiency.

Each compressor in the range comes complete with iConn, CompAir’s digital cloud platform to provide real-time insights to keep the compressor running at peak performance and to reduce the risk of downtime.

Reduced maintenance costs

Hinged and removable doors provide easy access to all major components, helping reduce routine service to minimise compressor downtime. Easy-clean parts, such as the clean-in-place heat exchangers and washable package pre-filtration, help simplify cleaning and extend the life of consumables.

Long-life components are designed to withstand up to 46˚C maximum ambient temperatures, with an optional 55˚C high ambient package available.

CompAir’s progressive V-Shield technology includes robust piping, maintenance-free hoses and elastomeric seals for reliable, leak-free connections.

Reliable supply of air

Air treatment is also prioritised throughout the design, with a full range of filtration, dryer and condensate management systems. An integrated condensate separator is included as standard to reduce moisture carryover, while the high-efficiency air filter is designed for 4,000 hours and provides real-time indication of when it requires replacing.

All models in the new DX90-160 (RS) range are equipped with iConn 4.0 as standard, CompAir’s smart, proactive real-time monitoring service.